Flank Milling Optimization

With MAX-5’s patented algorithm, dramatic cost savings can be realized using ruled-surface designs and production with a flank-milling process. Flank milling efficiently finishes the entire blade surface with one pass using the side of the cutter. Our algorithm analyzes and assesses the deviation for each blade and compensates for it to produce parts that meet very tight tolerances. The pictures below show views inside the tool to better view the reduced deviation:

Compared to other CAM systems, MAX-5 is often capable of generating flank milling toolpaths with an 80% to 90% error reduction with one pass on each side of the blade. The alternative, point milling with just the tool tip, requires many passes to leave a suitably small cusp height between passes. This dramatically increases the machining time of the part. The flank milling algorithm in MAX-5 also provides smooth machine motion without dangerous rotary spins that are a common pitfall of 5-axis machining.